Classifying apparatus, systems and methods

ABSTRACT

Hydrocyclones and related apparatus, systems and methods are disclosed for classifying aggregate material. Some embodiments include an inlet head with a spiral inlet having a height and width that vary along the direction of travel of material in the inlet head. Plants incorporating hydrocyclones are disclosed for classifying aggregate material. Some plant embodiments include an overflow container having a weir.

BACKGROUND

Classifying apparatus such as hydrocyclones and classifying plants(e.g., those including hydrocyclones, etc.) are used to wash and/orclassify material such as sand.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of an embodiment of a hydrocyclone.

FIG. 2 is a top plan view of the hydrocyclone of FIG. 1.

FIG. 3 is an exploded isometric view of the hydrocyclone of FIG. 1.

FIG. 4 is a partial expanded side elevation view of the hydrocyclone ofFIG. 1.

FIG. 5 is a partial plan view of the hydrocyclone of FIG. 1.

FIG. 6 is a cross-sectional view of the hydrocyclone of FIG. 1 along thesection 6-6 of FIG. 5.

FIG. 7 is a cross-sectional view of the hydrocyclone of FIG. 1 along thesection 6-6 of FIG. 5, illustrating exemplary flow paths.

FIG. 8 is an isometric view of an inlet head core of the hydrocyclone ofFIG. 1.

FIG. 9 is an isometric view of a taper section of the hydrocyclone ofFIG. 1.

FIG. 10 is a plan view of an underflow outlet of the hydrocyclone ofFIG. 1.

FIG. 11 is an isometric view of an inlet of the hydrocyclone of FIG. 1.

FIG. 12 is another isometric view of an inlet of the hydrocyclone ofFIG. 1.

FIG. 13 is an isometric view of a taper subsection of the hydrocycloneof FIG. 1.

FIG. 14 is a side elevation view of the taper subsection of FIG. 13along the section 6-6 of FIG. 5.

FIG. 15 is an expanded view of the detail area A15 of FIG. 14.

FIG. 16 is a perspective view of an embodiment of a plant incorporatingan embodiment of a hydrocyclone.

FIG. 17 is a perspective view of the plant of FIG. 16 with certaincomponents not shown for clarity.

FIG. 18 is a sectional view along the section B-B of FIG. 19.

FIG. 19 is a front elevation view of the plant of FIG. 16.

FIG. 20 is a plan view of an embodiment of a hydrocyclone inlet head.

FIG. 21 illustrates a schematic representation of the radialcross-section 20-20 of FIG. 20.

DESCRIPTION

Referring to the drawings, wherein like reference numerals designateidentical or corresponding parts throughout the several views, FIGS. 1-3illustrate a hydrocyclone 100. The hydrocyclone 100 optionally comprisesan inlet head 200 having a feed inlet 230 for receiving aggregatematerial (e.g., solids of varying density suspended in a liquid slurry,etc.) at an inlet opening I. The inlet head 200 optionally imposes acentripetal force on the aggregate material as the aggregate materialdescends along an optionally generally spiral path (e.g., the exemplarypath Ps shown in FIG. 7, etc.) along the circumferential walls of theinlet head into a taper section 300. The taper section 300 optionallycomprises a hollow frustum and is optionally mounted (e.g., removablymounted, etc.) to the inlet head 200 at a lower end thereof. Theaggregate material optionally descends in an optionally generally spiralpattern around circumferential walls of the taper section 300 into anoutlet 140 (e.g., along the exemplary path Ps shown in FIG. 7, etc.).The underflow outlet 140 is optionally mounted (e.g., removably mounted,etc.) to the taper section 300 at a lower end thereof. A first portionof the aggregate material (e.g., relatively coarse solids, etc.)optionally exits an underflow outlet apex 145 disposed at a lower end ofthe underflow outlet 140. The first portion of aggregate materialoptionally exits from the underflow outlet apex 145 into at an underflowoutlet opening Ou. A second portion of the aggregate material (e.g.,relatively fine solids and liquid, etc.) optionally forms a vortex whichoptionally ascends in a generally volute manner (e.g., along theexemplary path Pv shown in FIG. 7, which optionally has outer radialextents less than that of the exemplary path Ps, etc.) about a centralaxis Ac of the hydrocyclone 100 into a vortex finder 412 whichoptionally comprises a hollow tube extending vertically through a lid220 of the inlet head 200.

The vortex finder 412 optionally leads the second portion of aggregatematerial into an overflow discharge outlet 400. The discharge outlet 400optionally directs the second portion of aggregate material to anoverflow outlet opening. In some embodiments, the discharge outlet 400directs the second portion of aggregate material into a siphon 500having an outlet opening Oo disposed below the apex 145 of the outlet140.

Some hydrocyclone embodiments described herein may operate according oneor more operating principles disclosed in U.S. Pat. No. 4,317,716,incorporated by reference herein in its entirety.

Referring to FIGS. 3, 5 and 8, the feed inlet 230 optionally comprises ahollow conduit having an inlet opening I and an outlet opening in fluidcommunication with a spiral inlet section 210 of the inlet head 200. Inthe illustrated embodiment, the feed inlet 230 has a circular inletopening I and an optionally generally rectangular (e.g., generallysquare, etc.) outlet opening. The feed inlet 230 optionally comprises acircumferential wall 231 which optionally extends between the inletopening I and the outlet opening. In some embodiments, an inner surfaceof the circumferential wall 231 may transition (e.g., gradually,continuously, discontinuously, etc.) from a circular cross-section to agenerally rectangular (e.g., generally square, etc.) cross-section alongthe length of the feed inlet 230. The feed inlet 230 optionally includes(e.g., is formed as a part with, etc.) an inlet mounting flange 234having a plurality of mounting openings 235. The inlet mounting flange234 may have a generally circular shape as illustrated. The feed inlet230 optionally includes (e.g., is formed as a part with, etc.) an outletmounting flange 232 having a plurality of mounting openings 233. Theoutlet mounting flange 232 may have a generally rectangular (e.g.,generally square, etc.) shape as illustrated. The feed inlet 230 isoptionally made of a polymer (e.g., urethane or another polymer whichmay comprise a plastic or rubber, etc.) and may be formed by a castingprocess (e.g., resin casting, etc.).

The feed inlet 230 is optionally mounted to the inlet section 210 bybolts extending through mounting openings in a flange plate 242 (e.g., asteel flange, etc.), the mounting flange 232, and flange plates 214, 224on the inlet section. Upon installation, tightening of the boltsoptionally compresses the mounting flange 232 between the flange plate242 and the flange plates 214, 224, thus securing the feed inlet 230 inposition relative to the inlet section 210. Referring to FIG. 8, aninlet head core 600 (described in more detail herein) is optionally madeof a polymer (e.g., urethane or another polymer which may comprise aplastic or rubber, etc.) and may be formed by a casting process (e.g.,resin casting, etc.). The inlet head core 600 optionally includes aninlet flange 614 which is optionally flush with the flange plates 214,224 such that compression of the mounting flange 232 against the flangeplates 214, 224 optionally compresses a mating surface of the mountingflange 232 against a corresponding mating surface of the inlet flange614. A lid 220 of the inlet head 200 optionally includes a lid seal 222(not shown in FIG. 8). The lid seal 222 is optionally disposed betweenthe lid 220 (e.g., a metal lid, etc.) of the inlet head and the feedinlet in order to form an upper sealing surface of the inlet head core600. The lid seal 222 is optionally made of a polymer (e.g., urethane oranother polymer which may comprise a plastic or rubber, etc.). A matingsurface of the lid seal 222 is optionally flush with the flange plate224 and optionally forms a sealed contact area with the mounting flange232 of the inlet head at an upper end thereof.

Thus, when the feed inlet 230 is mounted to the inlet section 210, thelid seal 222 and the inlet flange 614 optionally form a circumferentialcompression seal with the outlet opening of the feed inlet 230.Referring to FIG. 12, one or more seals 237 optionally extendcircumferentially around the outlet openings of the feed inlet 230. Theseals 237 are optionally formed as a part with the mounting flange 232(in other embodiments, the seals 237 may be additionally oralternatively formed as a part with the flange 614 or may compriseseparate and/or separable sealing elements disposed between flanges 614,232, etc.). Each seal 237 may be generally semi-circular incross-section (e.g., when not compressed, etc.). A lower portion of eachseal 237 may have a curved surface corresponding to a lower portion ofthe flange 614 and optionally contacts the flange 614 when installed toform a sealed contact surface with the flange 614. An upper portion ofeach seal 237 optionally contacts the lid seal 222 when installed inorder to form a sealed contact surface with the lid seal 222.

Referring to FIG. 11, one or more seals 239 generally similar to theseal or seals 237 are optionally disposed generally circumferentiallyabout the inlet opening I of the feed inlet 230 and are optionallyformed as a part with the flange 234. The inlet I is optionally mountedto an inlet pipe (not shown) by bolting a mounting flange 234 between aflange plate 244 and a corresponding flange (not shown) of the inletpipe using mounting openings 235 and corresponding openings in theflange plate 244 and the flange of the inlet pipe. An optional annularspacer 260 is optionally disposed between the flange 234 and the inletpipe. When installed, the spacer 260 may include a pressure tap (notshown) in fluid communication with a pressure and/or flow measurementdevice such as a pressure gauge. The inlet pipe and the annular spacer260 optionally comprise a polymer such as high-density polyethylene(HDPE), which may comprise a different material from that comprising thefeed inlet 230 (e.g., urethane, etc.) and/or the inlet head core 600(e.g., urethane, etc.). Referring to FIG. 2, the inlet I and/or thespacer 260 optionally have an inner diameter Di-i. A diameter of eachseal 239 is optionally greater than Di-i and each seal 239 is optionallygenerally concentric with the inlet opening I such that each seal formsa continuous contact surface with the spacer 260.

The inner diameter Di-i is optionally selected to equal (orapproximately equal) corresponding standard inner diameters of pipeshaving the material of the inlet pipe (e.g., HDPE pipe, etc.). Inexemplary embodiments such as those in which the inlet pipe and/orspacer 260 are made of HDPE, the inner diameter Di-i may be equal to (orapproximately equal to) any of the following: 4.7 inches, 4.87 inches,5.8 inches, 6.24 inches, 7.5 inches, 7.55 inches, 9.4 inches, 11.16inches, 12.25 inches, 14 inches.

Referring to FIGS. 3, 5 and 8, the inlet head 200 optionally comprisesan inlet head core 600 and lid seal 222 (which may both compriseurethane or another polymer as described herein) disposed within a shell(e.g., a metal structure such as steel, etc.) comprising a spiral inletsection 210 and a generally cylindrical body 250. A flange 212optionally extends circumferentially about the upper surface of theinlet section 210 and body 250. The flange 212 optionally includesmounting openings corresponding to mounting openings in the lid 220 suchthat the lid 220 may be fastened to the upper surface of the inletsection 210 and body 250. The lid seal 222 is optionally of the sameshape as the lid 220 and optionally has mounting openings correspondingto those of the flange 212 and lid 220. The lid seal 222 (which maycomprise urethane or another polymer as described herein) is optionallymounted between the lid 220 and the upper surface of the inlet section210 and body 250. When installed, the lid seal 222 is optionally flushwith the upper surface 630 of the inlet head core 600 and optionallyforms a contact seal with the inlet head core 600, which contact sealoptionally protects the lid 220 (and other metal components of the inlethead 200) from contacting liquid and/or aggregate material travellingthrough the inlet head core 600.

One or more seals 632 optionally extends along the upper surface 630.When the lid seal 222 and lid 220 are installed, the seal or seals 632are optionally compressed between the upper surface 630 and the lid seal222. Each seal 632 is optionally formed as a part with the inlet headcore 600 and/or the surface 630, or alternatively maybe formed as a partwith the lid seal 222 or may comprise a separate sealing element. Eachseal 632 is optionally generally semi-circular in cross-section (e.g.,when not compressed). Each seal 632 optionally extends at leastpartially in a spiral manner. Each seal optionally extends on both sidesof a portion (e.g., inlet portion, spiral portion, etc.) of the path Ps(see FIG. 7).

Referring to FIG. 8, the inlet head core 600 optionally comprises aspiral inlet section 610 having a core inlet Ci at least partiallybounded by the flange 614. The inlet section 610 optionally defines achannel having an outer sidewall 628, an inner sidewall 626, and a lowersurface 622. The sidewalls 626, 628 optionally meet the lower surface622 at rounded fillets, although in alternative embodiments anon-filleted corner may exist between each sidewall and the lowersurface. The lower surface 622 optionally extends generally spirallyinward toward the central axis Ac. The lower surface 622 optionallydescends gradually (e.g., relative to the lid 220) along the directionof travel T of the aggregate material received from the feed inlet 230.

Referring to the embodiment of an inlet head core 2000 illustrated inFIG. 20, the inlet head core 2000 optionally comprises a spiral inletsection 2010 having a core inlet Ci. The inlet section 2010 optionallydefines a channel 2001 having an outer sidewall 2028, an inner sidewall2026, and a lower surface 2022. The inner sidewall 2026 optionallyterminates at or adjacent to a body inlet Bi. The lower surface 2022optionally extends generally spirally inward toward the central axis Ac.The lower surface 2022 optionally descends gradually (e.g., relative toa lid and/or upper surface of the channel 2001) along the direction oftravel T of the aggregate material (e.g., feed slurry, sand slurry,etc.).

Continuing to refer to FIG. 20, an angle Ar is optionally measured aboutthe central axis Ac between the channel inlet Ci (e.g., the outersidewall 2028 at the channel inlet) and a radial cross-section of thechannel 2001 such as section 20-20 schematically illustrated in FIG. 21.In some embodiments, each radial cross-section (such as that illustratedin FIG. 21) has a height H, a width W, and an area A. The values of H,W, and A each optionally vary with the angle Ar as described in moredetail below according to various embodiments. It is worth noting thatconnection of the lower surface 2022 with the inner sidewall 2026 andthe outer sidewall 2028 of section 20-20 of FIG. 21 is schematicallyillustrated with square corners. Those skilled in the art willappreciate that connection of the lower surface 2022 with the inner sidewall 2026 and the outer sidewall 2028 can include rounded corners havinga selected radius and the extent of the selected radius can be takeninto account when calculating the value of A.

In some embodiments, the height H increases (e.g., linearly,approximately linearly, etc.) with increasing values of the angle Ar. Invarious embodiments, the height H varies linearly or approximatelylinearly with the angle Ar with a slope of between 0.02 and 0.05,between 0.03 and 0.04, between 0.035 and 0.04, between 0.03 and 0.035,0.03, approximately 0.03, 0.031, approximately 0.031, 0.032,approximately 0.032, 0.033, approximately 0.033, 0.034, approximately0.034, 0.035, approximately 0.035, 0.036, approximately 0.036, 0.037,approximately 0.037, 0.038, approximately 0.038, 0.039, approximately0.039, 0.04, approximately 0.04, etc. In some embodiments, the variationbetween maximum and minimum values of the height H is greater than 30%,greater than 40%, greater than 50%, greater than 55%, about 55%, about60%, between 50% and 60%, between 55% and 65%, etc.

In some embodiments, the width W decreases (e.g., linearly,approximately linearly, etc.) with increasing values of the angle Ar. Invarious embodiments, the width W varies linearly or approximatelylinearly with the angle Ar with a slope of between −0.01 and −0.03,−0.01, approximately −0.01, −0.02, approximately −0.02, −0.03,approximately −0.03, between −0.01 and −0.02, between −0.02 and −0.03.In some embodiments, the variation between maximum and minimum values ofthe width W is greater than 30%, greater than 40%, greater than 50%,greater than 55%, about 55%, about 60%, between 50% and 60%, between 55%and 65%, etc.

In some embodiments, the area A initially increases with increasingvalues of the angle Ar (e.g., from 0 to a threshold angle, etc.) andthen decreases with increasing values of the angle Ar (e.g., from thethreshold angle to an angle corresponding to the terminal end of thechannel 2001, etc.). In some embodiments, the threshold angle is between70 and 80 degrees, about 70 degrees, about 75 degrees, about 80 degrees,between 73 and 77 degrees, etc. In some embodiments, the area A variesparabolically with the angle Ar. In some embodiments, the variationbetween maximum and minimum values of area A is less than 25%, less than20%, less than 15%, about 10%, less than 10%, less than 5%, between 5%and 15%, between 7% and 13%, between 9% and 13%, etc.

In some embodiments, the variation in the area A is less than 20%, thevariation in the height H is greater than 50% and the variation in thewidth W is greater than 50%.

In some embodiments, the variation in the area A is less than 15%, thevariation in the height H is greater than 50% and the variation in thewidth W is greater than 50%.

In some embodiments, the variation in the area A is less than 25%, thevariation in the height H is greater than 33% and the variation in thewidth W is greater than 33%.

Returning to FIGS. 3, 5, and 8, in some embodiments a stabilizingelement 227 (e.g., a bolt or metal tab, etc.) extends through lid 220into an opening 627 in the inlet head core 600 (e.g., adjacent to aportion of sidewall 626 distal from the feed inlet 230, etc.). Thestabilizing element 227 may extend through the lower ring 226 (e.g., aradially eccentric portion thereof, etc.).

The inner sidewall 626 optionally terminates at a body inlet Bi. Thebody inlet Bi optionally defines a material inlet through which inletmaterial flows from the inlet section 610 into a body 650 of the inlethead core 600. The body inlet Bi is optionally bounded an outer end bythe outer sidewall 628, at an inner end by the inner sidewall 626, at alower end by the lower surface 622, and at an upper end by the lid seal222. Turning to FIG. 6, a height H of the body inlet Bi may be measuredby a distance (e.g., a maximum distance, etc.) between the lower surface622 and the upper surface 630 (and/or the lid seal 222). A width W ofthe body inlet Bi may be measured by a distance (e.g., a maximumdistance, etc.) between the sidewalls 626, 628. A ratio H/W between theheight and width of the inlet Bi may be 3, approximately 3, between 2.5and 3.5, between 2.6 and 3.4, between 2.6 and 2.7, between 2.65 and 2.7,2.67, approximately 2.67, approximately 2.6, approximately 2.7, between2.7 and 3.3, between 2.8 and 3.2, between 2.9 and 3.1, between 2.95 and3.05, slightly less than 3, slightly greater than 3, between 2.8 and 3,between 2.9 and 3, between 2.95 and 3, between 3 and 3.05, between 3 and3.1, between 3 and 3.2, etc.). In an exemplary embodiment, the inlethead diameter Dc (e.g., the inner diameter of the inlet head sidewall652, etc.) is 24 inches (or approximately 24 inches, etc.), the height His approximately 12 inches (e.g., between 11.75 and 12 inches, 11.78inches, approximately 11.78 inches, 11.79, approximately 11.79, etc.)and the width W is approximately 4.5 inches (e.g., 4.4 inches,approximately 4.4 inches, between 4.3 and 4.5 inches, between 4.3 and4.4 inches, between 4.4 and 4.5 inches, etc.).

Returning to FIG. 8, the lower surface 622 optionally comprises aportion of a surface 620 which optionally also includes a surface 624which optionally extends in a generally spiral and descending mannerinto the interior volume 655 of the body 650 along the sidewall 652. Thewidth of the surface 624 optionally decreases along the direction ofinlet material travel.

In the illustrated embodiment, material entering the inlet Ci has ageneral velocity vector that does not intersect (e.g., extends generallytangential to) the body 650. However, in other embodiments the inletsection 610 may be reconfigured such that the material entering theinlet Ci has a general velocity that does intersect (e.g., extendstoward) the body 650.

Referring to FIGS. 3, 4, and 6, the taper section 300 is optionallymounted to the head by a mounting arrangement 340. The mountingarrangement 340 is shown in more detail in FIG. 4, in which portions ofconnecting bolts 344 are not shown for clarity. The mounting arrangement340 generally comprises a pair of optionally annular mounting plates342-1, 342-2 (e.g., made of metal such as steel, etc.). The mountingplates 342 are optionally fixed relative to one another by radiallyarranged bolts 344 extending through corresponding mounting holes ineach plate and nuts 346, although other devices may be used to fix therelative position of the mounting plates. A mounting flange 654 isoptionally formed as a part with (or otherwise joined to) a lowerportion of the inlet head core 600. The mounting flange 654 optionallyextends radially outwardly of the body 250 of the inlet head 200. Alower surface of mounting flange 654 optionally mates with an uppersurface of a mounting flange 312 of the taper section 300 to form anoptionally annular contact surface. Tightening of bolts 344 (orotherwise moving the mounting plates 342 closer together) optionallycompresses the mounting flanges 654, 312 together such that the annularcontact surface is effectively sealed to prevent aggregate material fromescaping. The bolts 344 optionally extend downward along axes disposedradially outwardly of the flanges 654, 312; in other embodiments, theflanges 654, 312 may be provided with mounting holes through which thebolts 344 extend. One or more optionally annular shims 349 (see FIG. 13)may be disposed between the mounting plates 342. The shim or shims 349optionally include mounting holes 348-1 (e.g., a radial array ofmounting holes) for partially receiving bolts 344. The mounting plates342 optionally include mounting holes 348-2 (e.g., a radial array ofmounting holes) each aligned with corresponding mounting holes in theopposing mounting plate and/or with mounting holes 348-1 in the shims349.

Referring to FIGS. 3 and 6, the taper section optionally comprises aplurality of taper subsections. Each taper subsection optionallycomprises a hollow frustum. In the illustrated embodiment, a first tapersubsection 310 is mounted at an upper end thereof to a lower end of theinlet head 200 by mounting arrangement 340 as described herein. A secondtaper subsection 320 is optionally mounted at an upper end thereof to alower end of the first taper subsection 310 by a mounting arrangement350 optionally generally similar to the mounting arrangement 340. Athird taper subsection 330 is optionally mounted at an upper end thereofto a lower end of the second taper subsection 310 by a mountingarrangement 360 optionally generally similar to the mounting arrangement340. The inner radius of the mating surfaces between the tapersubsections is optionally substantially equal such that downward flowalong the inner sidewalls of the taper subjections (e.g., a portion ofthe path Ps) is not disturbed by discontinuities along the inner surfaceof the taper section 300. The taper subsections 310, 320, 330 optionallycomprise cores 315, 325, 335 respectively; the cores may be made of apolymer such as urethane. The cores 315, 325, 335 are optionally encasedby shells 316, 326, 336 respectively; the shells may be made of a metalsuch as steel.

Turning to FIG. 9, the core 325 is illustrated in more detail; thedetails described herein may be representative of the cores of eachtaper subsection. The core 325 optionally comprises a tapered sidewall323 (e.g., a frustrum-shaped sidewall, etc.) extending between upper andlower mounting flanges 322, 324 respectively. The mounting flanges 322,324 optionally extend radially outwardly from the sidewall 323 andoptionally extend radially outwardly of the shell 326. The upper flange322 optionally has an upper surface 328 corresponding to and forming anoptionally annular contact surface with a flange disposed above thetaper subsection 320.

One or more seals 327 are optionally disposed on the upper surface 328.The seals 327 are optionally formed as a part with the mounting flange322 (in other embodiments, the seals 327 may be additionally oralternatively formed as a part with a lower surface of lower flange 324or may comprise separate and/or separable sealing elements disposedbetween flanges, etc.). The seals 327 optionally each have a thickness(e.g., measured from the mating surface of the mounting flange 322) lessthan the thickness of the mounting flange 322 (e.g., less than a fifthof the mounting flange thickness or less than a tenth of the mountingflange thickness, etc.). Each seal 322 may be generally semi-circular incross-section (e.g., when not compressed). In embodiments includingmultiple seals 327, the seals are optionally disposed in generallyconcentric fashion. Each seal 327 optionally contacts the adjacentmounting flange in order to form a sealed contact surface with theadjacent mounting flange.

Turning to FIGS. 13 through 15, a plurality of seals 317-1, 317-2 areillustrated disposed in a generally concentric fashion on the tapersubsection 310. The seals 317 are optionally disposed on (e.g., formedas a part with, etc.) a mounting flange 312 of the core 315, e.g., on anupper surface 313 thereof. The seals 317 optionally have an uncompressedheight Hs relative to surface 313 which is optionally selected to createa sealing effect when the taper subsection 310 is mounted to the inlethead 200. It should be appreciated that the seals 317 are illustrated intheir uncompressed state (e.g., in which the taper subsection 310 hasnot been mounted to the inlet head 200, etc.).

One or more optionally annular shims 349 are optionally disposed on theannular mounting plate 342-2. In alternative embodiments, the mountingplate 342-2 and shim 349 may comprise portions of a unitary structure.In the uncompressed state of the mounting flange 312 (e.g., in which thetaper subsection 310 has not been mounted to the inlet head 200, etc.),the upper surface 313 of the mounting flange 312 is optionally disposedhigher than an upper surface of an adjacent annular shim by a height Hg.The annular shim 349 optionally contacts another annular shim when thetaper subsection 310 is mounted to the inlet head 200; in order toachieve this contact, the height Hs of the seals 317 is optionallyreduced by compression of the seals 317 and/or the height Hg of thesurface 313 is optionally reduced by compression of the mounting flange312. Thus the height Hs and/or the height Hg are optionally selected topermit contact between adjacent shims 349 and/or between shims 349 andmounting plates 342. The height Hs and/or the height Hg are alsooptionally selected such that the installation compression (e.g., thecompression to achieve contact between shims 349 and/or between shims349, etc.) and mounting plates 342 is not sufficient to plasticallydeform the seals 317 and/or the flange 312. In an exemplary embodiment,the height Hs is 1/16 inches and the height Hg is 0.028 inches. Theheight Hs is optionally less than the thickness of the mounting flange312 (e.g., less than a third or less than a half of the thickness of themounting flange 312, etc.). The height Hg is optionally less than theheight Hs (e.g., approximately one-half of Hs, less than one half of Hs,approximately a third of Hs, etc.).

The seals 317 are optionally substantially semi-circular incross-sectional profile in their uncompressed state. Upon beingcompressed during installation, the seals are optionally deformed (e.g.,elastically, non-plastically, etc.) into a different cross-sectionalprofile (e.g., a substantially rectangular profile, etc.).

In some embodiments, other seals described herein (e.g., seals providedon the feed inlet, the inlet head core, each taper subsection and/or onthe underflow outlet, etc.) may have the dimensions (e.g., height Hs,etc.) and characteristics (e.g., semi-circular uncompressed shape, etc.)of the seals 317 described above. In some embodiments, other mountingflanges described herein (e.g., mounting flanges provided on each tapersubsection, etc.) may also extend upwardly from adjacent mountingstructure (e.g., optionally annular shims, etc.) in their uncompressedstate by a height (e.g., a height less than Hs such as Hg, etc.) asdescribed above.

In alternative embodiments, the taper section may comprise a differentnumber of taper subsections (e.g., 2 or 4, etc.) or may comprise asingle section (e.g., a single unitary section, etc.). Although in theillustrated embodiment the taper subsections have a substantiallyconstant taper angle, in alternative embodiments, the taper angle mayvary between the taper subsection. In alternative embodiments, the tapersubsections may be joined (and/or the taper section may be joined to theinlet head) differently than as illustrated in FIG. 4 (e.g., by weldingor by latches or other suitable structure).

Referring to FIGS. 3 and 10, the underflow outlet 140 is optionallymounted to the taper section at a lower end thereof by a mountingarrangement 370 generally similar to the mounting arrangement 340. Theunderflow outlet 140 is optionally made of a polymer such as urethane.

The underflow outlet 140 optionally includes a mounting flange at anupper end thereof having a mounting surface 143 for forming a contactsurface with a lower mounting flange of the taper section 300. Theflange 142 may include mounting openings 148 for receiving bolts orother fastening devices of the mounting arrangement 370.

One or more seals 147 are optionally provided on the mounting surface143. The seals 147 are optionally formed as a part with the mountingflange 142 (in other embodiments, the seals 147 may be additionally oralternatively formed as a part with the lower mounting flange of thetaper section 300 or may comprise separate and/or separable sealingelements disposed between flanges). The seals 147 optionally each have athickness (e.g., measured from the mating surface of the mounting flange232) less than the thickness of the mounting flange 142 (e.g., less thana fifth of the mounting flange thickness or less than a tenth of themounting flange thickness, etc.). Each seal 147 may be generallysemi-circular in cross-section (e.g., when not compressed). Inembodiments including multiple seals 147, the seals are optionallydisposed in generally concentric fashion. Each seal 147 optionallycontacts the lower flange of the taper section 300 when installed inorder to form a sealed contact surface with the lower flange.

The underflow outlet 140 optionally comprises tapered inner sidewall 144(e.g., forming a frustum, etc.). The upper end of the inner sidewall 144optionally comprises an opening through which material is exchangedbetween the underflow outlet 140 and the taper section 300. The lowerend of the inner sidewall 144 optionally comprises the underflow outletapex 145 through which materials escape the underflow outlet 140.

In some embodiments, a valve 150 such as a duckbill valve (e.g., made ofrubber and having an elongated lower outlet) may be mounted to theunderflow outlet at a lower end thereof (e.g., by one or more adjustableclamps 152 such as hose clamps, etc.) to modify the release of materialsfrom the underflow outlet 140 as described further herein. In otherembodiments, a splash skirt (e.g., made of metal, polymer or rubber,etc.) may be disposed around the apex 145. In still other embodiments,the underflow outlet 140 may simply release materials from the apex 145into atmosphere.

Referring to FIGS. 1-3, the overflow discharge outlet 400 is describedin more detail. The overflow discharge outlet 400 optionally includes aninlet pipe 410 for receiving overflow material. The inlet pipe 410 whichis optionally removably coupled to and in fluid communication with thevortex finder 412. In the illustrated embodiment, the inlet pipe 410 isremovably coupled to the vortex finder 412 by a mounting arrangementcomprising an upper ring 416 having a radial array of mounting openingsfor receiving a plurality of threaded rods. The threaded rods areoptionally screwed into threaded openings in a lower ring 226 which isoptionally fixed (e.g., by welding and/or bolting, etc.) to the lid 220.Movement of the upper ring 416 toward lower ring 226 (e.g., by screwingnuts onto the top of the threaded rods, etc.) optionally compressescorresponding mounting flanges of the inlet pipe 410 and vortex finder412 together, optionally creating a sealed contact surface.

Referring to FIG. 6, the vortex finder 412 optionally has an innerdiameter Dv-i. The inner diameter Dv-i is optionally selected from amongstandard inner diameters of pipes having the material of the outlet pipe430 (e.g., HDPE pipe, etc.) described below and/or downstream pipescoupled thereto. Additionally, the inner diameter Dv-i is optionallyselected such that a ratio between Dv-i and the inlet head diameter Dcis within an operationally effective range (e.g., between 0.25 and 0.5,between 0.3 and 0.4, 0.35, approximately 0.35, 0.39, approximately 0.39,etc.). In an exemplary embodiment in which the vortex finder 412 (and/orthe outlet pipe 430) are made of HDPE, the inlet head diameter Dc may be24 inches while the inner diameter Dv-i may be equal to (orapproximately equal to) 9.4 inches.

The overflow discharge outlet optionally includes an outlet pipe 430 influid communication with the inlet pipe 410 for receiving overflowmaterial. In some embodiments, the outlet pipe 430 extends generallynormal to the inlet pipe 410 (e.g., the outlet pipe 430 may extendgenerally horizontally as illustrated). The outlet pipe 430 isoptionally coupled to the inlet pipe 410 via a T-joint 420, although inother embodiments the pipes 410, 430 may be coupled via a pipe elbow(e.g., 90 degree elbow, etc.) or other structure.

The outlet pipe 430 may be removably coupled to a downstream pipe forfurther processing and/or may deposit overflow materials intoatmosphere. In the illustrated embodiment, the outlet pipe 430 isremovably coupled to a connecting pipe 510. The outlet pipe 430optionally includes a mounting flange 414 for mating the outlet pipe 430to the connecting pipe 510 or other downstream pipe structure. Themounting flange 414 optionally forms a sealed contact surface with acorresponding mounting flange 514 provided on the connecting pipe 510.Flange plates 432, 512 are optionally mounted together (e.g., usingbolts inserted in mounting openings which are optionally arranged on theflange plates) in order to compress together and optionally sealcorresponding faces of the mounting flanges 414, 514.

In the illustrated embodiment, the connecting pipe 510 comprises aportion of a siphon 500. The siphon 500 optionally has outlet disposedlower than the underflow outlet 140 and/or the valve 150 or other outletstructure mounted beneath the underflow outlet 140. In operation,opening an air inlet valve (not shown) in fluid communication with anair inlet 522 to a selected extent optionally allows air to flow intothe siphon 500. The selected state of the air inlet valve optionallydetermines the extent to which the valve 150 opens; for example, whenthe air inlet valve is closed and no air enters the air inlet 522,material traveling through the siphon 500 may create a vacuum inside thehydrocyclone 100 causing the valve 150 to close completely, whileprogressively opening the air inlet valve may allow the valve 150 toopen to progressively greater extent, allowing progressively largersizes and/or amounts of material to exit the valve 150. In otherembodiments, the amount or size of materials allowed to exit theunderflow may be modified by varying the size of the apex 145 (e.g., byremoving a bottom portion of the underflow outlet 140 and/or byreplacing the underflow outlet 140 with a different outlet having adifferently-sized apex, etc.).

The siphon 500 optionally includes an elbow 520 coupled to the pipe 510.The elbow 520 optionally places the pipe 510 in fluid communication witha downwardly extending pipe 530 which is optionally coupled to the elbow520 at an upper end thereof. An outlet Oo of pipe 530 is optionallydisposed below the underflow outlet 140 and/or the valve 150. The elbow520 is optionally in fluid communication with the air inlet 522 (e.g.,via an opening formed in an upper surface of the elbow 520). In someembodiments, a reducer 540 is optionally coupled to the outlet of thepipe 530 (e.g., removably coupled using a hose clamp 532, etc.).

The overflow discharge outlet 400 optionally includes a panel 445 (e.g.,an inspection panel and/or access panel, etc.). The panel 445 optionallypermits inspection of an internal volume of the overflow dischargeoutlet 400. The panel 445 optionally permits inspection of internalvolumes of the inlet head 200, the taper section 300, and/or theunderflow outlet 140. The panel 445 is optionally selectivelydisplaceable (e.g., removable) to permit inspection of and access to theinside of the hydrocyclone 100; in some embodiments, the panel 445 mayadditionally be at least partially transparent to allow inspectionwithout removal of the panel 445. The panel 445 is optionally disposedalong the central axis Ac of the hydrocyclone 100.

In the illustrated embodiment, the panel 445 is removably mounted to thepipe 440. The pipe 440 (e.g., a central axis thereof and/or an upperopening thereof) is optionally aligned with the vortex finder 412 (e.g.,a central axis thereof); for example, the pipe 440 is optionallyintersected by a vertical axis (e.g., hydrocyclone central axis Ac)which intersects the vortex finder 412. The panel 445 is optionallyremovably mounted to pipe 440 by attaching (e.g., bolting) the panel 445to a flange plate 444 such that the flange plate 444 and panel 445 aresecured to a mounting flange 442 provided on (e.g., formed as a partwith) the pipe 440. The panel 445 optionally forms a sealed contactsurface with the pipe 440 (e.g., with the mounting flange 442) such thatmaterials being processed do not escape an upper end of the pipe 440. Inalternative embodiments, the panel 445 may be selectively secured to thepipe 440 using a hinge or sliding coupling in conjunction with a latchor other suitable device.

The pipes of the overflow discharge outlet 400 optionally comprise apolymer such as HDPE. An inner diameter of the pipes (e.g., the innerdiameter Do-i of the pipe 430) is optionally a standard inner diameterof HDPE pipe; in some embodiments, the inner diameter Do-i is equal toor approximately equal to the inner diameter Dv-i of the vortex finder412.

Ranges recited herein are intended to inclusively recite all valueswithin the range provided in addition to the maximum and minimum rangevalues. Headings used herein are simply for convenience of the readerand are not intended to be understood as limiting or used for any otherpurpose.

Referring to FIGS. 16 and 17, a plant 1600 incorporating a hydrocyclone1610 is illustrated from a perspective view. In some embodiments, thehydrocyclone 1610 comprises any hydrocyclone embodiment describedherein. The plant 1600 generally comprises the hydrocyclone 1610, a sump1800, a pump 1680, and a classifier 1630 (e.g., a vibratory screen suchas a dewatering screen having one or more decks of horizontal orinclined screening media according to various embodiments, etc.).

In operation of some embodiments, an aggregate slurry enters an inlet1820 and is deposited (e.g., via a feed well, etc.) into the sump 1800.The pump 1680 optionally pumps aggregate slurry from the sump 1800(e.g., from a lower volume thereof, etc.) into an inlet of thehydrocyclone 1610 (e.g., via a conduit 1602 such as a pipe, etc.). Anunderflow outlet of the hydrocyclone 1610 optionally deposits underflowfrom the hydrocyclone onto the classifier 1630 and/or other equipmentfor further processing and/or transport. An overflow outlet of thehydrocyclone 1610 is optionally in fluid communication with a conduit1618 such as a pipe.

The overflow outlet of the hydrocyclone 1610 optionally communicatesaggregate slurry (e.g., overflow aggregate slurry) to an overflowcontainer 1700 (e.g., temporary overflow container). The overflowcontainer 1700 optionally includes an outlet 1790 for transfer ofoverflow aggregate slurry to storage and/or other equipment forprocessing, transfer, and/or storage. The overflow container 1700 isoptionally in fluid communication with the sump 1800 (e.g., via aconduit 1780).

Referring to FIG. 17, in which a housing 1702 (e.g., comprisingsidewalls or other structure) of the overflow container 1700 is notshown, a first weir 1710 is optionally disposed within the overflowcontainer 1700. The first weir 1710 optionally substantially isolateswater (e.g., below a first weir height thereof) from the outlet 1790.Thus overflow aggregate material communicated to the overflow container1700 is communicated to the sump 1800 (e.g., recycled) until theoverflow aggregate material in the overflow container 1700 exceeds thefirst overflow height of the first weir 1710. Overflow aggregatematerial in the overflow container 1700 exceeding the first weird heightpasses over the first weir 1710 and communicated out of the outlet 1790.

Recycled aggregate material communicated from the overflow container1700 to the sump 1800 is contained behind a second weir 1810 disposed inthe sump 1800 until the recycled aggregate material exceeds a secondweir height of the second weir 1810. Recycled aggregate materialexceeding the second weir height passes over the second weir 1810 into aprimary interior volume of the sump 1800 (e.g., the interior volume fromwhich the pump 1680 communicates aggregate material into thehydrocyclone 1610). The second weir 1810 may comprise a wall disposed inthe sump 1800. In some embodiments such as the illustrated embodiment,the second weir height is the height of a lower edge of an opening inthe second weir 1810; in other embodiments, the second weir height isthe height of an upper edge of the second weir 1810.

In some embodiments, the first weir height is equal or approximatelyequal to (e.g., within 1 inch, ½ inch, or ¼ inch of, etc.) the secondweir height. In other embodiments, the first weir height is greater than(more than 1 inch, more than 2 inches, more than 3 inches or more than 5inches greater than, etc.) the second weir height. In still otherembodiments, the second weir height is greater than (more than 1 inch,more than 2 inches, more than 3 inches or more than 5 inches greaterthan, etc.) the first weir height. In yet other embodiments, the firstweir and/or the second weir are vertically adjustable such that thefirst and/or second weir heights may be adjusted.

Although various embodiments have been described above, the details andfeatures of the disclosed embodiments are not intended to be limiting,as many variations and modifications will be readily apparent to thoseof skill in the art. Accordingly, the scope of the present disclosure isintended to be interpreted broadly and to include all variations andmodifications within the scope and spirit of the appended claims andtheir equivalents. For example, any feature described for one embodimentmay be used in any other embodiment.

1. A hydrocyclone for classifying aggregate material, comprising: a feedinlet; and an inlet head in fluid communication with said feed inlet,said inlet head comprising: a generally cylindrical body portion, saidbody portion having a central vertical axis; and a spiral inlet in fluidcommunication with said body portion via a body inlet, said body inletcomprising a terminal end of said spiral inlet, said spiral inlet havingan inlet width measured between a first sidewall of said spiral inletand a second sidewall of said spiral inlet, said spiral inlet having aninlet height measured between a lower surface of said spiral inlet andan upper surface of said spiral inlet, said spiral inlet having across-sectional inlet area along a plane extending through said centralvertical axis, wherein an inlet angle is measured about said centralvertical axis from an inlet opening of said spiral inlet along a traveldirection of aggregate material entering said spiral inlet; a vortexfinder extending at least partially into said body portion of said inlethead, wherein said vortex finder has a vortex finder diameter, whereinsaid inlet head has an inlet head diameter, wherein a ratio of saidvortex finder diameter to said inlet head diameter is between 0.25 and0.5; an overflow outlet in fluid communication with said vortex finder;and an underflow outlet in fluid communication with said body portion ofsaid inlet head, said underflow outlet disposed beneath said bodyportion.
 2. The hydrocyclone of claim 1, wherein said inlet heightincreases with said inlet angle.
 3. The hydrocyclone of claim 1, whereinsaid inlet width decreases with said inlet angle.
 4. The hydrocyclone ofclaim 1, wherein said inlet area varies parabolically with said inletangle.
 5. The hydrocyclone of claim 1, wherein said inlet area increaseswith said inlet angle from said inlet opening to a threshold value ofsaid inlet angle, and wherein said inlet area decreases with said inletangle from said threshold value of said inlet angle to said body inlet.6. The hydrocyclone of claim 1, wherein said inlet area varies by lessthan 25% with said inlet angle.
 7. The hydrocyclone of claim 6, whereinsaid inlet height varies by more than 50% with said inlet angle.
 8. Thehydrocyclone of claim 7, wherein said inlet width varies by more than50% with said inlet angle.
 9. The hydrocyclone of claim 1, wherein saidbody portion of said inlet head comprises a first mounting surface,further comprising: a taper subsection having a second mounting surface,wherein said first and second mounting surfaces are mounted together toform a continuous contact area; and a seal provided on one of said firstand second mounting surfaces, the seal having a compressed state and anuncompressed state, wherein said seal prevents escape of materials fromsaid contact area.
 10. The hydrocyclone of claim 1, wherein said feedinlet comprises a feed inlet opening and a feed inlet outlet opening,wherein said feed inlet opening has a different cross-section than saidfeed inlet outlet opening, and wherein said feed inlet opening has aninner diameter corresponding to a standard inner diameter for a pipemade of a second material, wherein said second material comprises astandard pipe material.
 11. The hydrocyclone of claim 10, wherein saidfirst material comprises urethane, and wherein said second materialcomprises high-density polyethylene.
 12. The hydrocyclone of claim 1,wherein a ratio of said inlet height to said inlet width at said bodyinlet is between 2.8 and 3.2.
 13. The hydrocyclone of claim 1, whereinsaid vortex finder is in fluid communication with an overflow outlet,wherein said overflow outlet comprises: an inlet pipe, said inlet pipebeing aligned with said vortex finder.
 14. A hydrocyclone forclassifying aggregate material, comprising: an inlet head in fluidcommunication with said feed inlet, said inlet head comprising: agenerally cylindrical body portion said body portion having a centralvertical axis, a spiral inlet in fluid communication with said bodyportion via a body inlet, said body inlet comprising a terminal end ofsaid spiral inlet, said spiral inlet having an inlet width measuredbetween a first sidewall of said spiral inlet and a second sidewall ofsaid spiral inlet, said spiral inlet having an inlet height measuredbetween a lower surface of said spiral and an upper surface of saidspiral inlet, said spiral inlet having a cross-sectional inlet areaalong a plane extending through said central vertical axis, wherein saidfeed inlet is made of a first material, said feed inlet having a feedinlet opening and a feed inlet outlet opening, wherein said feed inletopening has a different cross-section than said feed inlet outletopening, and wherein said feed inlet opening has an inner diametercorresponding to a standard inner diameter for a pipe made of a secondmaterial, wherein said second material comprises a standard pipematerial; a vortex finder extending at least partially into said bodyportion of said inlet head; an overflow outlet in fluid communicationwith said vortex finder; and an underflow outlet in fluid communicationwith said body portion of said inlet head, said underflow outletdisposed beneath said body portion.
 15. The hydrocyclone of claim 14,wherein a ratio of said inlet height to said inlet width at said bodyinlet is between 2.8 and 3.2.
 16. The hydrocyclone of claim 14, whereinsaid inlet height increases with said inlet angle.
 17. The hydrocycloneof claim 14, wherein said inlet width decreases with said inlet angle.18. The hydrocyclone of claim 14, wherein said body portion of saidinlet head comprises a first mounting surface, wherein said hydrocyclonefurther comprises: a taper subsection having a second mounting surface,wherein said first and second mounting surfaces are mounted together toform a continuous contact area; and a seal provided on one of said firstand second mounting surfaces, the seal having a compressed state and anuncompressed state, wherein said seal prevents escape of materials fromsaid contact area.
 19. The hydrocyclone of claim 14, wherein said vortexfinder is in fluid communication with an overflow outlet, wherein saidoverflow outlet comprises: an inlet pipe, said inlet pipe being alignedwith said vortex finder.
 20. The hydrocyclone of claim 14, wherein saidfirst material comprises urethane.
 21. The hydrocyclone of claim 14,wherein said second material comprises high-density polyethylene. 22.The hydrocyclone of claim 14, wherein said vortex finder has a vortexfinder diameter, wherein said inlet head has an inlet head diameter,wherein a ratio between said vortex finder diameter and said inlet headdiameter is between 0.25 and 0.5.